Heat Exchanger Having an Integral Air Guide

ABSTRACT

A heat exchanger ( 40 ) includes a first header ( 42 ), a second header ( 44 ), and a plurality of tubes ( 46 ) extending between the first and second headers ( 42, 44 ). First and second extension members ( 48, 52 ) project from and are longitudinally oriented along a frontward facing side ( 50 ) of the headers ( 42, 44 ). The first and second extension members ( 48, 52 ) serve as guides for facilitating airflow through the heat exchanger ( 40 ). Third and fourth extension members ( 54, 58 ) project from and are longitudinally oriented along a rearward facing side ( 56 ) of the headers ( 42, 44 ). The third and fourth extension members ( 54, 58 ) serve to seal a gap between the heat exchanger ( 40 ) and an adjacent radiator ( 26 ), and guide airflow from the heat exchanger ( 40 ) through the radiator ( 26 ).

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the field of air management in avehicular front end. More specifically, the present invention relates toa heat exchanger for a vehicle having an air guide.

BACKGROUND OF THE INVENTION

A motor vehicle, such as an automobile, truck, and the like, typicallyhas an engine compartment located at the front of the vehicle. Aradiator, that is part of the engine's cooling system, is typicallymounted in front of the engine in the engine compartment. When thevehicle is equipped with air conditioning, a condenser mounts in frontof the radiator. The condenser and radiator are cooled by air thatpasses through them. The air may be forced through the condenser andradiator by ram air effect when the vehicle is in forward motion, and/orby being drawn through the condenser and radiator by a cooling fantypically located directly behind the radiator.

FIG. 1 shows a perspective exploded view of a portion of an enginecompartment of a vehicle 20. The engine compartment is schematicallyportrayed in FIG. 1 and is generally referred to as engine compartment22 which contains an engine 24, also portrayed schematically. A firstheat exchanger, in the form of a radiator 26 for engine 24, is disposedin front of engine 24, and a cooling fan 28 is located between radiator26 and engine 24. A second heat exchanger, in the form of a condenser 30for a vehicular air conditioning system, is disposed in front ofradiator 26.

Seals 32 are typically positioned between condenser 30 and radiator 26.Seals 32 form a tight seal between condenser 30 and radiator 26 so thatair forced through condenser 30 is pulled through radiator 26, ratherthan around radiator 26. The flow of air around radiator 26 can resultin inefficient cooling of engine 24, which can lead to undesirable andpotentially damaging overheating of engine 24. In addition, seals 32function to prevent the build-up of debris between the front of radiator26 and the back of condenser 30. Debris in this area undesirablyobstructs the flow of air through radiator 26 which again can lead tooverheating of engine 24.

Condenser 30 generally includes a plurality of condenser tubes 34extending between a first header 36 and a second header 38, each ofwhich have a generally circular cross-section. First and second headers36 and 38 feed high-pressure refrigerant from the compressor (not shown)into condenser tubes 34 where it is cooled until it returns to itsliquid state, in accordance with well known methodologies.

A problem with prior art condenser/radiator cooling systems, such ascondenser 30 and radiator 26, is that of insufficient airflow throughcondenser 30 and radiator 26. This problem can even arise in new systemsthat have not yet been contaminated with debris. Insufficient airflowthrough condenser 30 and radiator 26 undesirably hinders heat rejectionfrom condenser 30 and radiator 26. Insufficient airflow and acommensurate reduction in heat rejection is exacerbated when the vehicleis traveling in low-speed and/or high-load operating conditions, whenthe vehicle is traveling in “stop-and-go” conditions, and when thevehicle is simply idling.

Insufficient heat rejection at condenser 30 can cause an increase inhead pressure of the air conditioning system, thereby reducing airconditioner cooling performance. An increase in head pressure canadditionally increase the power consumption of the air conditioningcompressor thereby reducing gas mileage. Insufficient heat rejection atradiator 26 can reduce engine cooling system performance, therebyresulting in elevated temperatures in engine compartment 22. Theseelevated temperatures may be sufficiently high to create thermallyinduced problems in certain components of the vehicle.

Another problem with systems such as that described above, is that seals32 between condenser 30 and radiator 26 can be breached or can fall offdue to moisture, salt, heat, cold, adhesive issues, and age-relatedissues. The failure of seals 32 can lead to further airflowinefficiencies through radiator 26, and can lead to the undesirableaccumulation of debris between condenser 30 and radiator 26.

Accordingly, what is needed is a guide for facilitating airflow througha heat exchanger, and especially through a condenser and radiator of avehicle. What is further needed is a durable means for sealing betweenthe condenser and radiator.

SUMMARY OF THE INVENTION

Accordingly, it is an advantage of the present invention that a heatexchanger for a vehicle is provided that facilitates airflow through theheat exchanger.

Another advantage of the present invention is that a heat exchanger, inthe form of a condenser, is provided that enhances heat rejection by thecondenser and an adjacent radiator.

Another advantage of the present invention is that a heat exchanger, inthe form of a condenser, is provided that eliminates utilization of aseparate sealing element between the condenser and an adjacent radiator.

The above and other advantages of the present invention are carried outin one form by a heat exchanger that includes a first header, a secondheader, and a plurality of tubes extending between the first and secondheaders. An extension member projects from, and is longitudinallyoriented, along one of the first and second headers.

The above and other advantages of the present invention are carried outin another form by a heat exchanger configured for installation in avehicle. The heat exchanger includes a first header, a second header,and a plurality of tubes extending between the first and second headers.A first extension member projects from, and is longitudinally orientedalong, a frontward facing side of the first header, and a secondextension member projects from, and is longitudinally oriented along,the frontward facing side of the second header.

The above and other advantages of the present invention are carried outin yet another form by a heat exchanger configured for installation in avehicle. The heat exchanger includes a first header, a second header,and a plurality of tubes extending between the first and second headers.A first extension member projects from, and is longitudinally orientedalong, a rearward facing side of the first header, and a secondextension member projects from, and is longitudinally oriented along,the rearward facing side of the second header.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the Figures, wherein like reference numbers refer tosimilar items throughout the Figures, and:

FIG. 1 shows an exploded perspective view of a portion of an enginecompartment of a vehicle;

FIG. 2 shows a perspective view of a heat exchanger in accordance with apreferred embodiment of the present invention;

FIG. 3 shows a cross-sectional view of a header of the heat exchanger ofFIG.2;

FIG. 4 shows an exploded perspective view of a portion of an enginecompartment of a vehicle including the heat exchanger of FIG. 2;

FIG. 5 shows a perspective view of the heat exchanger proximate aradiator;

FIG. 6 shows a perspective view of a heat exchanger in accordance with afurther embodiment of the present invention;

FIG. 7 shows a cross-sectional view of a header of the heat exchanger ofFIGS. 2 and 6 in accordance with an alternative embodiment of thepresent invention; and

FIG. 8 shows a cross-sectional view of a header of the heat exchanger ofFIGS. 2 and 6 in accordance with another alternative embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention entails a guide for improving air managementthrough a heat exchanger. This improvement in air management isdescribed in connection with heat exchangers found in the front end ofvehicles. These heat exchangers include, for example, a condenser and aradiator. However, it will become apparent to those skilled in the artthat the present invention may be adapted for various heat exchangerdesigns, and is not limited to heat exchangers for use in vehicles.

Referring to FIGS. 2-4, FIG. 2 shows a perspective view of a heatexchanger 40 in accordance with a preferred embodiment of the presentinvention. FIG. 3 shows a cross-sectional view of a first header 42 ofheat exchanger 40, and FIG. 4 shows an exploded perspective view of aportion of engine compartment 22 of vehicle 20 including heat exchanger40.

For purposes of illustration, heat exchanger 40 is a condenser for avehicle air conditioning system, the remaining components of which arenot shown. As such the heat exchanger illustrated in FIGS. 2-4 will bereferred to hereinafter as condenser 40. In addition, condenser 40 canreadily replace condenser 30 of vehicle 20, illustrated in FIG. 1.Accordingly, comparable components from FIG. 1 retain the same referencenumerals in FIG. 4.

Condenser 40 includes first header 42 and a second header 44. Aplurality of tubes 46 extends between first and second headers 42 and44, respectively, for passing refrigerant between first and secondheaders 42 and 44. First header 42 includes a first extension member 48projecting from, and longitudinally oriented along, a frontward facingside 50 of first header 42. Similarly, second header 44 includes asecond extension member 52 projecting from, and longitudinally orientedalong, frontward facing side 50 of second header 44. First header 42further includes a third extension member 54 projecting from, andlongitudinally oriented along, a rearward facing side 56 of first header42. Likewise, second header 44 includes a fourth extension member 58projecting from, and longitudinally oriented along, rearward facing side56 of second header 44.

For clarity of understanding, the term “frontward facing side” utilizedherein generally refers to the side of condenser 40 that faces frontwardin vehicle 20, while the term “rearward facing side” generally refers tothe side of condenser 40 that faces backward, or toward engine 24, invehicle 20.

In a preferred embodiment, first and third extension members 48 and 54,respectively, project from first header 42 substantially perpendicularrelative to tubes 46, as most clearly illustrated in FIG. 3. Inaddition, third extension member 54 diametrically opposes firstextension member 48 on an outer surface 60 of first header 42. That is,first and third extension members 48 and 54, respectively, are locatedon opposite sides, and along the diameter of first header 42. Likewise,second and fourth extension members 52 and 58, respectively, projectfrom second header 44 substantially perpendicular relative to tubes 46,and fourth extension member 58 diametrically opposes second extensionmember 52 on an outer surface 62 of second header 44.

Each of first and second headers 42 and 44, respectively, may be formedfrom two sections that are bonded together. As most clearly illustratedin FIG. 3, first header 42 includes a first section 64 from which firstextension member 48 extends, and a second section 66 from which thirdextension member 54 extends. First section 64 has a first pair oflongitudinally oriented edges 68, and second section 66 has a secondpair of longitudinally oriented edges 70. First and second pairs ofedges 68 and 70 can be welded, brazed, or otherwise adhered to oneanother during manufacturing to form first header 42. Alternatively, andas known to those skilled in the art, first and second headers 42 and44, respectively, may be shaped into a continuous form utilizing aconventional extrusion manufacturing technique. The outcome of either ofthe manufacturing techniques is first and third extension members 48 and54, respectively, integrally formed with first header 42, and second andfourth extension members 52 and 58 integrally formed with second header44.

Referring to FIG. 5, in connection with FIGS. 2-4, FIG. 5 shows aperspective view of condenser 40 proximate radiator 26. As shown,radiator 26 is positioned proximate rearward facing side 56, and thirdand fourth extension members 54 and 58, respectively, extend towardradiator 26. In such a capacity, third and fourth extension members 54and 58 form a seal between first and second headers 42 and 44,respectively, and radiator 26. Consequently, third and fourth extensionmembers 54 and 58 can be utilized in place of seals 32 (FIG. 1). Thus,greater durability of the sealing mechanism is achieved through theutilization of third and fourth extension members 54 and 58 that areintegral to first and second headers 42 and 44, respectively. Inaddition, cost savings are achieved, through the elimination of thematerial cost of seals 32 and the labor cost for installation of seals32.

As well known to those skilled in the art, in a vapor compressionsystem, vapor refrigerant is compressed in the compressor, where itstemperature is raised above the temperature of the cooling medium usedat the condenser. Vaporized refrigerant then enters condenser 40, andinto tubes 46, where heat is rejected from the refrigerant, and therefrigerant changes to a liquid. The liquid refrigerant subsequentlyexits from condenser 40 and enters a thermal expansion valve (notshown), which controls the quantity of liquid refrigerant passing to theevaporator coils (not shown). Finally, the liquid refrigerant enters theevaporator and evaporates. Heat from the ambient atmosphere, forexample, in a vehicle passenger compartment, is rejected to therefrigerant in the evaporator where it is absorbed as the latent heat ofvaporization as the refrigerant evaporates. The now vaporizedrefrigerant is then directed to the compressor to be recycled throughthe system.

First and second extension members 48 and 52, respectively, serve asguides to direct airflow entering at the front of vehicle 20 throughcondenser 40 at frontward facing side 50, rather than around condenser40. Third and fourth extension members 54 and 58 seal the gap betweencondenser 40 and radiator 26, and guide airflow from condenser 40through radiator 26, rather than around radiator 26.

First and second extension members 48 and 52 facilitate an increase inairflow through condenser 40 and, correspondingly, radiator 26 overprior art systems, such as condenser 30 (FIG. 1). An increase of airflowthrough condenser 40 and radiator 26 improves vehicle air conditioningsystem and engine cooling system performance, especially in low-speedand/or high-load operating conditions, when the vehicle is traveling in“stop-and-go” conditions, and when the vehicle is simply idling. Morespecifically, increased airflow through condenser 40 and radiator 26results in higher heat rejection from condenser 40 and radiator 26.

Higher heat rejection from condenser 40 reduces the head pressure of theair conditioning system, thereby improving system performance, orcoefficient of performance (COP). Consequently, the vent outlet andcabin temperatures improve, resulting in increased comfort for thepassengers. In addition, a reduction in head pressure reduces powerconsumption by the compressor resulting in improved gas mileage, and acommensurate reduction in tail pipe emissions. Similarly, higher heatrejection from radiator 26 results in improved engine cooling, therebyreducing the potential for engine component failure.

In a preferred embodiment, condenser 40 has both frontward facing firstand second extension members 48 and 52, respectively, and rearwardfacing third and fourth extension members 54 and 58, respectively.However, it should be understood that modifications thereof are withinthe scope of the present invention, and depend upon particular designconsiderations. For example, a condenser may include frontward facingfirst and second extension members 48 and 52, but not rearward facingthird and fourth extension members 54 and 58. As such, the conventionalseals 32 (FIG. 1) might be used with such a condenser. In anotherconfiguration, a condenser might include rearward facing third andfourth extension members 54 and 58, but not the frontward facing firstand second extension members 48 and 52, so as to replace the lessdurable conventional seals 32.

FIG. 6 shows a perspective view of condenser 40 in accordance with afurther embodiment of the present invention. Condenser 40 has beenmodified to illustrate an additional feature of the present invention.As shown, each of first extension member 48 of first header 42 andsecond extension member 52 of second header 44 has been modified toinclude a fastening portion 72.

Fastening portion 72 is a region on each of first and second extensionmembers 48 and 52 that is configured to enable attachment of a separatestructure. Fastening portion 72 may include holes, clip nuts,indentations, and so forth that facilitate the attachment of a separatestructure. In this exemplary scenario, the separate structure is an oilcooler 73. Oil cooler 73 is a small heat exchanger that is utilized tocool the engine oil or the automatic transmission fluid. As air passesthrough oil cooler 73, heat from the oil is rejected to the air.Accordingly, oil cooler 73 can benefit from increased heat rejectionproduced utilizing first and second extension members 48 and 52 formanaging airflow through oil cooler 73, and correspondingly, condenser40 and radiator 26. Other structures may optionally be coupled to firstand second extension members 48 and 52, such as fluid supply lines, andthe like.

FIG. 7 shows a cross-sectional view of a header 74 for condenser 40(FIG. 2) in accordance with an alternative embodiment of the presentinvention. Header 74 may be utilized in place of first header 42. Itshould be understood however, that replacement of second header 44 (FIG.2) with a header having the features of header 74, will be a mirrorimage of header 74.

A first extension member 76 projects from, and extends longitudinallyalong frontward facing side 50 of header 74. A second extension member78 projects from, and extends longitudinally along rearward facing side56 of header 74. As shown, first extension member 76 projects in such adirection so as to form an acute angle 80 between first extension member76 and tubes 46 (shown in ghost form). Such a configuration mayeffectively channel airflow through condenser 40 (FIG. 2), whileconcurrently addressing space design considerations within enginecompartment 22 (FIG. 4).

FIG. 8 shows a cross-sectional view of a header 82 for the condenser 40(FIG. 2) in accordance with another alternative embodiment of thepresent invention. Header 82 may also be utilized in place of firstheader 42. It should be understood however, that replacement of secondheader 44 (FIG. 2) with a header in accordance with the features ofheader 82, will be a mirror image of header 82.

A first extension member 84 projects from, and extends longitudinallyalong frontward facing side 50 of header 82. A second extension member86 projects from, and extends longitudinally along rearward facing side56 of header 82. As shown, first extension member 84 projects in such adirection so as to form an obtuse angle 88 between first extensionmember 84 and tubes 46 (shown in ghost form). Such a configuration mayserve to funnel additional air through condenser 40 and radiator 26(FIG. 2) to further enhance heat rejection, when there is enough spaceto accommodate the outwardly flared first extension member 84.

In summary, the present invention teaches of a heat exchanger for avehicle that facilitates airflow through the heat exchanger. The heatexchanger, in the form of a condenser, includes extension membersprojecting from a frontward facing side of the headers that improveairflow through the condenser and an adjacent radiator to enhance heatrejection by same. In addition, the heat exchanger includes extensionmembers projecting from a rearward facing side of the headers that forma durable seal between the condenser and the adjacent radiator, so thatseparate sealing elements need not be employed.

Although the preferred embodiments of the invention have beenillustrated and described in detail, it will be readily apparent tothose skilled in the art that various modifications may be made thereinwithout departing from the spirit of the invention or from the scope ofthe appended claims. For example, when a condenser is not used in avehicle, the vehicular radiator may include extension sections thatfunnel, or channel, airflow through the radiator. In addition, extensionmembers integral to the headers may be adapted for use with a variety ofheat exchangers.

1. A heat exchanger comprising; a first header; a second header; aplurality of tubes extending between said first and second headers; andan extension member projecting from, and longitudinally oriented along,one of said first and second headers.
 2. A heat exchanger as claimed inclaim 1 wherein said heat exchanger is configured for installation in avehicle and said extension member projects from a frontward facing sideof said one of said first and second headers.
 3. A heat exchanger asclaimed in claim 1 wherein said heat exchanger is configured forinstallation in a vehicle and said extension member projects from arearward facing side of said one of said first and second headers.
 4. Aheat exchanger as claimed in claim 3 wherein said vehicle furthercomprises a radiator positioned proximate said rearward facing side ofsaid one of said first and second headers, and said extension memberprojects toward said radiator to form a seal between said one of saidfirst and second headers and said radiator.
 5. A heat exchanger asclaimed in claim 1 wherein said extension member projects substantiallyperpendicular relative to said plurality of tubes.
 6. A heat exchangeras claimed in claim 1 wherein said extension member projects in adirection to form an acute angle between said extension member and saidplurality of tubes.
 7. A heat exchanger as claimed in claim 1 whereinsaid extension member projects in a direction to form an obtuse anglebetween said extension member and said plurality of tubes.
 8. A heatexchanger as claimed in claim 1 wherein said extension member is a firstextension member, and said heat exchanger further comprises a secondextension member projecting from, and longitudinally oriented along,another of said first and second headers.
 9. A heat exchanger as claimedin claim 1 wherein said extension member is a first extension member,and said heat exchanger further comprises a second extension memberprojecting from, and longitudinally oriented along, said one of saidfirst and second headers.
 10. A heat exchanger as claimed in claim 9wherein said second extension member diametrically opposes said firstextension member on an outer surface of said one of said first andsecond headers.
 11. A heat exchanger as claimed in claim 9 wherein saidone of said first and second headers comprises: a first section having afirst pair of longitudinally oriented edges, said first extension memberextending from said first section; and a second section having a secondpair of longitudinally oriented edges bonded to said first pair oflongitudinally oriented edges, said second extension member extendingfrom said second section.
 12. A heat exchanger as claimed in claim 1wherein said extension member further comprises a fastening portionconfigured to enable attachment of a separate structure.
 13. A heatexchanger configured for installation in a vehicle comprising: a firstheader; a second header; plurality of tubes extending between said firstand second headers; first extension member projecting from, andlongitudinally oriented along, a frontward facing side of said firstheader; and second extension member projecting from, and longitudinallyoriented along, said frontward facing side of said second header.
 14. Aheat exchanger as claimed in claim 13 further comprising; a thirdextension member projecting from, and longitudinally oriented along, arearward facing side of said first header; and a fourth extension memberprojecting from, and longitudinally oriented along, said rearward facingside of said second header.
 15. A heat exchanger as claimed in claim 14wherein said vehicle further comprises a radiator positioned proximatesaid rearward facing side of said first and second headers, and saidthird and fourth extension members project toward said radiator to forma seal between said first and second headers and said radiator.
 16. Aheat exchanger as claimed in claim 14 wherein: said third extensionmember diametrically opposes said first extension member on a firstouter surface of said first header; and said fourth extension memberdiametrically opposes said second extension member on a second outersurface of said second header.
 17. A heat exchanger as claimed in claim14 wherein each of said first and second headers comprises: a firstsection having a first pair of longitudinally oriented edges, and anassociated one of said first and second extension members extends fromsaid first section; and a second section having a second pair oflongitudinally oriented edges bonded to said first pair oflongitudinally oriented edges, and an associated one or said third andfourth extension members extends from said second section.
 18. A heatexchanger as claimed in claim 13 wherein each of said first and secondextension members further comprises a fastening portion configured toenable attachment of a separate structure.
 19. A heat exchangerconfigured for installation in a vehicle comprising: a first header; asecond header; a plurality of tubes extending between said first andsecond headers; a first extension member projecting from, andlongitudinally oriented along, a rearward facing side of said firstheader; and a second extension member projecting from, andlongitudinally oriented along, said rearward facing side of said secondheader.
 20. A heat exchanger as claimed in claim 19 wherein said vehiclefurther comprises a radiator positioned proximate said rearward facingside of said first and second headers, and said first and secondextension members project toward said radiator to form a seal betweensaid first and second headers and said radiator.